Thermoformed wall and fencing assemblies

ABSTRACT

Plastic panels are thermoformed to include a variety of three-dimensional features resembling masonry patterns, various types of walls, and fencing sections. The thermoformed panels are incorporated into fencing and wall assemblies. A fencing assembly includes plastic panels thermoformed to resemble a plurality of stakes. Panels are disposed between a pair of posts with side portions configured to overlap. Each stake includes a top return projecting rearwardly. Horizontal reinforcements couple the panels to the posts. A double-sided wall assembly employs plastic panels thermoformed to resemble bricks and other wall patterns. Each sub-assembly includes a pair of panels coupled to a frame in a back-to-back arrangement. The sub-assemblies are disposed side-by-side in between a pair of posts.

This is a divisional application of application Ser. No. 10/609,030filed on Jun. 26, 2003, which is a divisional application of applicationSer. No. 09/928,153 filed on Aug. 10, 2001, now U.S. Pat. No. 6,719,277.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to thermoplastic fencing, walland building structures.

2. Description of Prior Art and Related Information

Until recently, fences have typically been composed of wood or metal.Wooden fences include several drawbacks. Such fences are susceptible toa great deal of wear and tear caused by natural elements, such as heat,wind and rain. The cost of the wood itself can be quite high, especiallyif a fence needs to be replaced. Corrugated metallic fences includeseveral drawbacks as well. Not only is the metal subject to corrosion,but metallic fence sheets lack rigidity and dent easily. In addition tothe susceptibility to deterioration, metallic fences tend to present aflimsy and cheap appearance.

As an alternative to wood fences, thermoplastic fencing assemblies havebeen provided with components formed to resemble wood fencingstructures. Such thermoplastic assemblies include extruded, hollow tubesshaped to resemble planks. The “planks” are joined by horizontal “rails”and coupled to posts, all of which also consist of plastic, extrudedtubes. Though such thermoplastic assemblies do not deteriorate in thesame manner as does wood, the plastic fences of the prior art have theirown disadvantages.

With respect to cost, the prior art assemblies include “planks” that areindividually extruded. In particular, each plank consists of aseparately extruded tube. As extruded tubes with hollow cores and openends, caps are required to cover at least the tops of each tube in orderto preserve aesthetics. Having to extrude each plank separately,however, leads to high costs. Each plank must then be secured to one ormore horizontal rails, which increases costs and complexities related toassembly.

A further disadvantage of existing plastic fences includes the inabilityto withstand heat. Fences are generally provided for the outdoors wherethey are subject to the sun. In prior art plastic fences, eachindividual plank is extruded as a hollow tube, with a thin layer ofplastic material. If the tubes are dark colored, a greater amount ofheat from the sun is absorbed and captured within their hollow cores.The heat absorption exacerbated by dark colored tubes causes the thintubes to deform.

SUMMARY OF THE INVENTION

The present invention provides structures and methods which overcome thedeficiencies in the prior art.

In one aspect, a fence assembly is provided. The fence assemblycomprises a thermoformed panel, a reinforcement coupled to the panel,and a post coupled to the panel. The thermoformed panel comprises a top,a bottom, a first axis defined between the top and the bottom, aplurality of stakes, with each stake extending parallel to the firstaxis and having a top return extending perpendicular to the first axis,and a nestable side portion. Each rearwardly projecting top returncomprises a rounded curved shape. Each stake comprises a major portionand a minor portion that meet at a forwardly protruding ridge.

The assembly further comprises a side cover coupled to a side portion ofthe panel and a bottom flange. The reinforcement comprises a hollow barand a solid insert disposed within the bar. The assembly furthercomprises a flat vertical portion disposed between each stake, whereinthe reinforcement is welded to the flat vertical portions.

In another aspect, a fence assembly comprises a first post, a secondpost, a first thermoformed panel having a first plurality of verticallyextending stakes with top returns, and a first side portion, and asecond thermoformed panel having a second plurality of verticallyextending stakes with top returns, and a second side portion configuredto overlap the first side portion of the first thermoformed panel. Thefirst thermoformed panel is disposed side-by-side with the secondthermoformed panel such that the second side portion overlaps the firstside portion. The first thermoformed panel and the second thermoformedpanel are disposed in between the posts. The first thermoformed panel iscoupled to the first post, and the second thermoformed panel is coupledto the second post. The assembly further comprises horizontalreinforcements coupled to the panels. The first side portion comprises afirst laterally extending flange. The second side portion comprises aforwardly extending flange connected to a second laterally extendingflange.

A double-sided wall structure is also provided. The structure comprisesa frame having a first side and an opposite second side, a firstthermoformed panel coupled to the first side of the frame, and a secondthermoformed panel coupled to the second side of the frame. The firstthermoformed panel comprises a first three-dimensional, non-extrudablefront surface and a first rear surface substantially parallel to thefirst front surface. The second thermoformed panel comprises a secondthree-dimensional, non-extrudable front surface and a second rearsurface substantially parallel to the second front surface. The framecomprises at least a top horizontal beam, a bottom horizontal beam, afirst vertical beam and a second vertical beam.

The structure further comprises a support bar coupled to the tophorizontal beam of the frame and a support bar coupled to the bottomhorizontal beam of the frame. Side covers are coupled to at least aportion of the structure perimeter, namely to first and second sides ofthe structure. A post is coupled to the frame. The first rear surfacecomprises a first plurality of flat sections. The second rear surfacecomprises a second plurality of flat sections. The frame is coupled tothe first and second plurality of flat sections.

In a further aspect, a double-sided wall assembly comprises a firstsub-assembly, a second sub-assembly, a first post, and a second post.The first sub-assembly comprises a first frame, and a first pair ofthermoformed panels coupled to opposite sides of the first frame. Eachof the first pair of thermoformed panels has a front surface and a rearsurface. The panels of the first pair are coupled to the first frame ina back-to-back configuration. The second sub-assembly comprises a secondframe, and a second pair of thermoformed panels coupled to oppositesides of the second frame. Each of the second pair of thermoformedpanels has a front surface and a rear surface. The panels of the secondpair are coupled to the second frame in a back-to-back configuration.The first sub-assembly and the second sub-assembly are disposedside-by-side and in between the posts.

The assembly further comprises a first pair of brackets coupling thefirst sub-assembly to the first post, and a second pair of bracketscoupling the second sub-assembly to the second post. The assemblyfurther comprises a first, upper support bar and a second, lower supportbar juxtaposed in an overlapping relationship with the first frame andsecond frame. A top cover and a bottom cover are disposed over the firstsub-assembly and the second sub-assembly.

A method for manufacturing a fencing assembly is provided. The methodcomprises the steps of thermoforming a panel to form a three-dimensionalfront surface and a rear surface substantially parallel to the frontsurface, providing a thermoplastic post, and coupling a reinforcement toa rear surface of the panel. The step of thermoforming a panel comprisesthe step of forming a plurality of stakes and returns. The step ofproviding a thermoplastic post comprises the steps of extruding a hollowtube and injection molding a cap. The step of coupling a reinforcementto a rear surface of the panel comprises the step of adhering thereinforcement to the rear surface of the panel.

A method for assembling a plastic fence comprises the steps of couplinga first thermoformed panel to a first post, disposing a secondthermoformed panel adjacent to the first thermoformed panel, overlappinga first side portion of the first thermoformed panel with a second sideportion of the second thermoformed panel, removing a portion of thesecond thermoformed panel to leave a cut-off edge, covering the cut-offedge of the second thermoformed panel with a side cover, and couplingthe second thermoformed panel to a second post.

A method for manufacturing a double-sided wall assembly comprising thesteps of thermoforming a first panel to form a first three-dimensionfront surface and a substantially parallel first rear surface,thermoforming a second panel to form a second three-dimension frontsurface and a substantially parallel second rear surface, and forming aframe with a first side and a second side. The step of thermoforming thefirst panel comprises the step of forming the first panel with a firstplurality of flat portions. The step of thermoforming the second panelcomprises the step of forming the second panel with a second pluralityof flat portions. The step of forming the frame comprises the step ofproviding horizontal bars and vertical bars configured to abut the firstplurality of flat portions and the second plurality of flat portions.The step of thermoforming the first panel comprises the step of formingthe first panel with a first plurality of flat portions. The step ofthermoforming the second panel comprises the step of forming the secondpanel with a second plurality of flat portions.

A method for assembling a double-sided wall assembly is provided aswell. The method comprises the steps of coupling a first pair ofthermoformed panels to a first frame in a back-to-back configuration toform a first sub-assembly, coupling a second pair of thermoformed panelsto a second frame in a back-to-back configuration to form a secondsub-assembly, placing the first sub-assembly side-by-side with thesecond sub-assembly, coupling the first sub-assembly to a first post,and coupling the second sub-assembly to a second post. The methodfurther comprises the steps of removing a portion of the secondsub-assembly to expose a cut-off edge, and covering the cut-off edgewith a side cover. A vertical support may be coupled to the cut-off edgeof the second sub-assembly. The step of covering the cut-off edge of thesecond sub-assembly with a side cover comprises the step of covering thevertical support.

In summary, plastic panels are thermoformed to include a variety ofthree-dimensional features resembling masonry patterns, various types ofwalls, and fencing sections. The thermoformed panels are incorporatedinto fencing and wall assemblies. A fencing assembly includes plasticpanels thermoformed to resemble a plurality of stakes. Panels aredisposed between a pair of posts with side portions configured tooverlap. Each stake includes a top return projecting rearwardly.Horizontal reinforcements couple the panels to the posts. A double-sidedwall assembly employs plastic panels thermoformed to resemble bricks andother wall patterns. Each sub-assembly includes a pair of panels coupledto a frame in a back-to-back arrangement. The sub-assemblies aredisposed side-by-side in between a pair of posts.

The invention, now having been briefly summarized, may be betterappreciated by the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevation view of a preferred embodiment of a fencepanel according to the invention;

FIG. 2 is a rear perspective view of the preferred embodiment of thefence panel;

FIG. 3 is a cross-sectional view of the preferred fence panel takenalong lines 3-3 of FIG. 1;

FIG. 4 is a cross-sectional view of the preferred fence panel takenalong lines 4-4 of FIG. 1;

FIG. 5 is a cross-sectional view of the preferred fence panel takenalong lines 5-5 of FIG. 1;

FIG. 6 is a cross-sectional view of the preferred fence panel takenalong lines 6-6 of FIG. 1;

FIG. 7 is a front elevation view of a further preferred embodiment of afence panel according to the invention;

FIG. 8 is a rear exploded, perspective view of a preferred embodiment ofa fencing assembly;

FIG. 9 is a front elevation view of the preferred embodiment of thefencing assembly;

FIG. 10 is a top plan view of the preferred embodiment of the fencingassembly;

FIG. 11 is a top plan view, in part, of a further preferred embodimentof a fencing assembly;

FIG. 12 is an exploded perspective view of a preferred embodiment of adouble-sided wall sub-assembly according to the invention;

FIG. 13 is a partially exploded front view of the preferred embodimentof the wall structure;

FIG. 14 is a top plan view of the preferred embodiment of the wallstructure in part; and

FIG. 15 is a top plan view, in part, of the preferred embodiment of thewall structure incorporating a side cover.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The invention and its various embodiments can now be better understoodby turning to the following detailed description wherein illustratedembodiments are described. It is to be expressly understood that theillustrated embodiments are set forth as examples and not by way oflimitations on the invention as ultimately defined in the claims.

In a first preferred embodiment shown in FIGS. 1 and 2, a wall panel 10is thermoformed into an integral, thermoplastic fence section resemblinga plurality of stakes, or planks, 30 grouped together. A Y axis isdefined between a top 25 and a bottom 27 of the panel 10. The stakes 30thus extend vertically and substantially parallel to the Y-axis. Sincethe fence section 10 is preferably composed of a thermoplastic material,such as polyvinyl chloride (PVC), the thickness of the wall of thesection 10 is roughly 0.05 inch to 0.15 inch. The panel 10 comprises anexternal, or front, surface 21 and an opposite internal, or rear,surface 23. Each “stake” 30 comprises a majority section 32 and aminority section 34 that meet at an outward ridge 36 and extendrearwardly therefrom to creases 38. The sections 32, 34, ridges 36, andcreases 38 are preferably vertically extending. The stakes 30 arepreferably identical with one another to allow for nesting as will bedescribed further below.

Since the panel 10 is thermoformed and relatively thin, the frontsurface 21 is substantially parallel to the rear surface 23. Thus, eachfront ridge 36 on the front surface 21 shown in FIG. 1 corresponds to arear crease 61 defined in the opposite rear surface 23 while a frontcrease 38 corresponds to a rear ridge 63. Each stake 30 includes arearwardly projecting flange, or top return, 41. In the preferredembodiment, each top return 41 is rounded to form a “dog ear” designwhich may be perceived as a more desirable design. The returns 41 notonly give the appearance of three-dimensional depth, but also provideextra rigidity. Similarly, the wall panel 10 includes a rearwardlyprojecting bottom flange 43 that provides additional strength. Inparticular, the top returns 41 and bottom flange 43 prevent the panel 10from buckling along the vertical ridges 36 and creases 38. Each stake 30includes a rear recess 65 defined by the vertical sections 32, 34, topreturn 41 and bottom flange 43.

It will be appreciated that the thermoforming process enables a panel tobe formed with structural features, such as flanges and returns, whichextend in a direction that is discontinuous with the remainder of thepanel, such as the vertical sections. In the conventional extrusionprocess, an extruded body maintains a constant cross-section, orprofile, throughout the axial length of the body. An extruded panel,therefore, may only be formed with linear, continuous sections thatextend parallel to the axis defined by an extrusion die. Thermoforming,on the other hand, enables a panel to have “non-extrudable” structuralfeatures, including three-dimensional discontinuous texture, that issimply impossible to accomplish with extrusion. Thus, a thermoformedpanel may have an irregular or variable profile along any axis of thepanel.

For example, FIGS. 3 and 4 are vertical cross-sectional views takenalong different points of the X-axis of the panel 10 shown in FIG. 1. Itwill be noted that the profiles are dissimilar. Likewise, FIGS. 5 and 6,which are horizontal cross-sectional views taken along different pointsalong the Y-axis of the panel 10 shown in FIG. 1, also illustratedifferent profiles. In FIGS. 5 and 6, it will be noted that a relativelynarrow flat section 45 is provided between each stake 30.

A laminate or other finishing layer 67 may be disposed on both the frontsurface 21 and rear surface 23 for aesthetics. Alternatively, it may bepreferable and cost efficient to provide the finishing layer on thefront surface 21 only. The finishing layer 67 may includethree-dimensional texture for a more aesthetically pleasing appearance.

The panel 10 further comprises side portions 70, 72 adapted to overlapwith each other, as best shown in FIGS. 5 and 6. A first side portion 70preferably comprises a flat, vertical flange. The opposite, second sideportion 72 includes a forwardly extending flange 74 that connects to alaterally extending flange 76. The laterally extending flange 76 istherefore configured to overlap and cover the front surface of a sideportion of an adjacent panel, as will be described below in connectionwith a preferred fencing assembly.

FIG. 7 illustrates a further preferred embodiment of a fencing panel 10a wherein structural elements similar to those previously discussed aredesignated by the same reference numeral followed by the letter “a”. Thepanel 10 a is thermoformed to include an integral rail 80. It is to beunderstood that more rails may be provided. Each rail 80 comprises anoutward rectangular flat portion 82 coupled to the rest of the panel 10a by a pair of outwardly extending flanges 84. Along with the topreturns 41 and the bottom flanges 43 a, the forwardly projecting rail 80reinforces the rigidity of the panel 10 by preventing buckling along thevertical ridges 36 a and creases 38 a. Likewise, the vertical ridges 36a and creases 38 a prevent buckling along the horizontal creases 86 ofthe rail 80.

In FIGS. 8-10, a preferred embodiment of a fencing assembly 100incorporates a plurality of the preferred fence panels 10 as describedabove. As an example and not by way of limitation, two panels 10 aredisposed between a pair of posts 112 although more or less panels 10 maybe provided between a pair of posts 112. The posts 112 preferablycomprise a hollow tube 114 topped with an ornamental cap 116. The tube114 preferably comprises a rectangular cross-section and thus includesfour sides 118. The tube 114 is preferably extruded while the cap 116 ispreferably injection molded.

To give the appearance of a unitary, continuous fence, the two fencepanels 10 are placed side-by-side and disposed in a slightly overlappingrelationship. In particular, a side portion 72 of the first panel 10overlaps and covers the front surface of an adjacent side portion 70 ofthe second panel 10. As best shown in the top plan view of FIG. 10, thecovering side portion 72 includes the forwardly extending flange 74 andlaterally extending flange 76 as described above. The covered sideportion 70 comprises a flat vertical section that is nested in the areadefined by the adjacent flanges 74, 76. It will be noted that theforwardly extending flange and laterally extending flange (not shown)has been removed from the panel 10 comprising the covered side portion70.

One or more horizontal reinforcements 120 may be provided. In thepreferred embodiment, top and bottom reinforcements 120 are provided.Each reinforcement 120 preferably comprises a pair of thermoplastichollow bars 122, each bar 122 being coupled to its corresponding fencepanel 10 on the rear surface 23 preferably by adhesion. In the preferredembodiment, the bars 122 are preferably rectangular so as to provide aflat surface that abuts the flat sections 45 of the panels 10. The bars122 are preferably composed of a thermoplastic material and may beadhered to the panels 10 with adhesive material, such as polyvinylchloride cement. The bars 122 are aligned to receive an insert 124 whichis then fastened to the pair of bars 122. Outer end portions 126 of thebars are coupled to the posts 112, preferably by brackets 130. Verticalsupports (not shown) may be optionally disposed in the stake recesses 65adjacent to the rear creases 61. In the preferred embodiment, the posts112 and reinforcement bars 122 are composed of a thermoplastic material,such as polyvinyl chloride.

To allow for adjustability in the width of the fence assembly 100, aside cover 132 is provided and configured to resemble a stake. The sidecover 132, which is preferably composed of the same thermoplasticmaterial as the panels 10, comprises a first flat portion 134 adapted tobe coupled to the post 112 and disposed between the post 112 and thenarrowed panel 10. A second, slanted portion 136 extends from the firstflat portion 134.

In a preferred method of assembly, an unwanted portion of a fence panel10 may be removed prior to being joined to a post 112, thereby yieldinga side edge 138 which may be unsightly. Accordingly, the correspondingreinforcement bars 122 of the narrowed panel 10 must be shortened. Theside cover 132 is coupled to the post 112. The narrowed panel 10 is thencoupled to the post 112. As a result, the slanted portion 136 overlaps aside portion of the narrowed panel 10 and gives the continuousappearance of another stake while covering the rough side edge 138 fromfrontal view.

FIG. 11 is a top plan view, in part, of another preferred embodiment ofa fence assembly 100 b wherein structural elements similar to thosepreviously discussed are designated by the same reference numeralfollowed by the letter “b”. The fence assembly 100 b incorporates afurther preferred embodiment of a fence panel 10 b wherein the flat sideflanges 70, 74, 76 shown in FIGS. 1, 3 and 4 have been omitted. As aresult, two panels 10 b may be placed side-by-side and disposed in anoverlapping relationship by having an outer stake 30 b, or a portionthereof, of one panel 10 b nest within the outer stake 30 b of theother, adjacent panel 10 b.

In the above illustrated embodiments, the fence assembly is shown ashaving two panels 10 disposed in between a pair or posts 112. Anexpanded fence assembly may be provided by coupling additional panels toany of the unattached sides of the posts 112 and adding further posts.Since the posts 112 preferably comprise a tube with a rectangularprofile having four sides, it will be appreciated that additional panelsmay be coupled to any of the unused sides to form perpendicular fencesections which may be preferable in fencing off areas of land. The tube114, however, may be formed in a variety of polygonal profiles, therebyvarying the number of sides available for coupling to additional panels.For example, a post may comprise a hexagonal tube 114 which would thenprovide six surfaces to which fence panels may be coupled. This may givea user greater flexibility, for example, in bordering corners of landthat are not right angles. The tubes 114 of the posts 112 according tothe invention are formed with a thickness preferably about 0.125 inch.

It will be appreciated that an elongated fencing assembly may be formedwith a plurality of the fence sections 10 according to the invention.With increasing needs for environmental preservation, an inexpensivealternative is provided for wood fencing which is just as aestheticallypleasing and even longer lasting. Furthermore, unlike conventionalplastic fences in which each individual stake is extruded, the fencingsection 10 according to the invention is much less expensive since aplurality of stakes may be formed in a single, integral panel. Since thepanel 10 is thermoformed, three-dimensional features, such as the topflanges 43, bottom flange 45, and the corrugation of the stakes 30,collectively give the panel 10 an impression of depth and volume when,in fact, the thickness of the panel is, for example, only 0.06 inch inthe preferred embodiment.

In the preferred embodiments, the wall panels comprise solid sheetswithout holes or openings. As fencing assemblies, this feature of thewall panel provides greater privacy than conventional fences. It is tobe expressly understood, however, that apertures may be formed in thepanels if desired. In the fence panel 10 shown in FIGS. 1-6, aperturesmay be formed, for example, by removing portions of the minority portion34 of the stakes 30.

In another aspect, a double-sided wall assembly according to theinvention may be provided with wall panels thermoformed to resemble avariety of different wall structures. In FIGS. 12-15, a preferredembodiment of a double-sided wall assembly incorporating thermoformedpanels is illustrated and designated generally by the reference numeral200. As described above, thermoforming enables panels to be formed withdiscontinuous structural features that are impossible to achieve byextrusion. In FIGS. 12-15, the wall assembly 200 includes panels 210thermoformed to resemble a brick wall section. It is to be understoodthat a variety of masonry patterns may be formed.

Each panel 210 comprises a front surface 212 and a rear surface 214. Aplurality of forwardly protruding “bricks” 216 are formed with recessed“grout lines” 218 horizontally and vertically dividing the bricks 216.The rearwardly protruding grout lines 218 correspond to flat rearsurfaces which provide surface area for abutting a frame as describedfurther below. A border 230 of the panel 210 comprises flat side flanges232 and flat top and bottom flanges 234. The outwardly raised frontsurface 212 may include finer three-dimensional texture, such asasymmetrical bumps and grooves, to give a more realistic andaesthetically pleasing appearance of bricks. For example, the preferredembodiment includes a Slumpstone texture. Other textures may beemployed.

For ease of manufacturability, the wall panel 210 may simply comprisetwo alternating rows 240 a, 240 b of differing structure. More or lessrows of differing structure may be provided. In the embodimentillustrated in FIG. 12, a Running Bond pattern of bricks is configured.It is to be expressly that a variety of different patterns may bethermoformed into the panel, such as basket weave, herringbone, stackbond, stone, rock, and more.

In the preferred embodiment shown in FIG. 13, the wall assembly 200includes two panel sub-assemblies, or double-sided wall structures, 250disposed side-by-side in between a pair of posts 252. More or less panelsub-assemblies may be provided between a pair of posts 252. Each panelassembly 250 includes a frame, or skeleton, 254 which comprises aplurality of vertical bars 256 and horizontal bars 258. The framedefines opposite sides 260, 261. A pair of panels 210 are coupled to theopposite sides 260, 261 of the frame 254, such as with fasteners, in aback-to-back arrangement with the rear surfaces 214 facing each other.Accordingly, the front surfaces 212 of the pair of panels 210 faceoutwardly and away from each other.

Side covers 262, each defining a U-channel, are coupled to the sides 262of each panel sub-assembly 250. The panel sub-assemblies 250 are coupledto each in a side-by-side arrangement. In the preferred embodiment, atop horizontal bar 258 of the frame 254 is offset from and disposedbeneath top edges 266 of the panels 210. A bottom horizontal bar 258 isalso offset from and disposed above the bottom edges 270 of the panels210. Accordingly, top and bottom spaces 272, 274, respectively, areprovided for receiving reinforcing members, or support bars, 276 whichmay be composed of metal, for example. In the preferred embodiment, atop reinforcing member 276 is disposed in the top space 272 bridging thetwo panel assemblies 250. Similarly, a bottom reinforcing member 276 isdisposed in the bottom space 274. The reinforcing members 276 arecoupled to the frame 254. Thus, each reinforcing member 276 isjuxtaposed in an overlapping relationship with both frames 254. A dowel,or pin, 277 couples the two sub-assemblies 250 together. The pin 277 isinserted through the side covers 262 and the vertical bars 256 of theframes 254. A clip 299 fixed over the pin 277 keeps the pin 277stationary by preventing any lateral movement between the sub-assemblies250.

A single top end cover and bottom end cover 280, 282, respectively, arepreferably disposed across both panel sub-assemblies 250. The top andbottom end covers 280, 282 define U-channels. With the spaces 272, 274provided by the offset horizontal frame bars 264, 268, respectively, itwill be appreciated that the reinforcement members 276 received thereinmay be substantially flush with the top edges 266 and bottom edges 270of the panels 210.

In the preferred embodiment, a pair of L-flanges, or brackets, 284 arecoupled to each post 252 so as to define a slot 286 for receiving thepanel sub-assemblies 250. A variety of mechanisms may be employed tocouple the panel sub-assemblies 250 to the posts 252. The posts 252preferably comprise a hollow tube 286 topped with an ornamental cap 288.

It will be appreciated that an elongated wall structure may be formed byproviding additional panel sub-assemblies and posts and coupling suchadditional structures to the wall structure 200.

The wall assembly 200 also provides adjustability in width as shown inFIG. 15. For example, a user may desire a specific width between thepair of posts 252 that is different from the width provided bypre-manufactured panels 210. In such a case, an unwanted portion (notshown) of a panel sub-assembly 250 may be removed so as to provide thedesired width. For example, by making a vertical cut, an unwanted sideportion of a panel sub-assembly 250, including portions of the frame andopposing side panels, may be removed to leave the remainder of the panelassembly 250 with the desired width. A vertical frame bar, or verticalsupport, 290 may be coupled to the edge 292 from which the unwantedportion has been removed. To maintain a continuous and aestheticallypleasing appearance, a side cover 294 according to the invention iscoupled to the panel assembly 250. The side cover 294 includes a centralrecess, or central U-channel, 296 defined by a pair of central flanges298 joined by a middle flange 302. The U-channel is configured toreceive and cover the projecting vertical frame bar 290 that has beenadded. Outer flanges 304 are configured to cover the unsightly edges 292of the cut panels 210. The outer flanges 304 are joined by connectingflanges 306 to the central flanges 298. The side cover 294 is alsoconfigured to fit within the slot 286 defined by the L-flanges 284.

With the side cover 294 coupled to the reduced panel sub-assembly 250,the sub-assembly 250 may then be coupled to the post 252 by insertingthe side cover 294, namely the central U-channel, into the slot 286. Inthe preferred embodiment of the wall assembly 200, the panels 210, posts252, covers 262, 280, 282, 294 are composed of a thermoplastic material,such as polyvinyl chloride.

It will be appreciated that the double-sided wall assembly 200 accordingto the invention may incorporate wall panels thermoformed in a varietyof designs. For example, a wall panel may be thermoformed to resemble abrick wall with an uneven array of bricks. In particular, each brick maybe configured to be outwardly or inwardly disposed relative to adjacentbricks so as to form an uneven pattern. As further examples, the wallpanel may be thermoformed to resemble other masonry patterns.

The above embodiments may be erected in open space to serve as a fencearound an open piece of property. The unique heat dissipationcharacteristic of the thermoformed panels according to the inventionalso enable a variety of dark colors to be applied. The panels accordingto the invention comprise unitary sheets without cavities. Since nopockets exist in which absorbed heat can build up, the heat absorbed bythe panels simply dissipates into the ambient environment. With theexcellent heat dissipating qualities of the panels due to the lack ofcavities, it will be appreciated that the fencing and wall assembliesaccording to the invention may be painted a variety of dark colors, suchas redwood brown, to resemble a natural wood fence or siding.Furthermore, the posts may optionally include solid inserts, such aswood studs, disposed in the cavity in order to prevent the tube fromwarping.

Many alterations and modifications may be made by those having ordinaryskill in the art without departing from the spirit and scope of theinvention. Therefore, it must be understood that the illustratedembodiments have been set forth only for the purposes of examples andthat they should not be taken as limiting the invention as defined bythe following claims. For example, notwithstanding the fact that theelements of a claim are set forth below in a certain combination, itmust be expressly understood that the invention includes othercombinations of fewer, more or different elements, which are disclosedin above even when not initially claimed in such combinations.

The words used in this specification to describe the invention and itsvarious embodiments are to be understood not only in the sense of theircommonly defined meanings, but to include by special definition in thisspecification the generic structure, material or acts of which theyrepresent a single species.

The definitions of the words or elements of the following claims are,therefore, defined in this specification to not only include thecombination of elements which are literally set forth. In this sense itis therefore contemplated that an equivalent substitution of two or moreelements may be made for any one of the elements in the claims below orthat a single element may be substituted for two or more elements in aclaim. Although elements may be described above as acting in certaincombinations and even initially claimed as such, it is to be expresslyunderstood that one or more elements from a claimed combination can insome cases be excised from the combination and that the claimedcombination may be directed to a subcombination or variation of asubcombination.

Insubstantial changes from the claimed subject matter as viewed by aperson with ordinary skill in the art, now known or later devised, areexpressly contemplated as being equivalently within the scope of theclaims. Therefore, obvious substitutions now or later known to one withordinary skill in the art are defined to be within the scope of thedefined elements.

The claims are thus to be understood to include what is specificallyillustrated and described above, what is conceptionally equivalent, whatcan be obviously substituted and also what incorporates the essentialidea of the invention.

1-52. (canceled)
 53. A method of manufacturing a double-sided wallassembly, comprising: thermoforming a first panel to form a firstthree-dimensional front surface and a first rear surface; thermoforminga second panel to form a second three-dimensional front surface and asecond rear surface; forming a first panel sub-assembly by facing thefirst rear surface of the first panel towards the second rear surface ofthe second panel; thermoforming a third panel to form a thirdthree-dimensional front surface and a third rear surface; thermoforminga fourth panel to form a fourth three-dimensional front surface and afourth rear surface; forming a second panel sub-assembly by facing thethird rear surface of the third panel towards the fourth rear surface ofthe fourth panel; and coupling the first panel sub-assembly to thesecond panel sub-assembly in a side-by side arrangement.
 54. The methodof claim 53, wherein coupling the first panel sub-assembly to the secondpanel sub-assembly in the side-by side arrangement comprises: couplingthe first panel sub-assembly and the second panel sub-assembly to apost.
 55. The method of claim 53, wherein: thermoforming the first panelto form the first three-dimensional front surface and the first rearsurface comprises forming the first three-dimensional front surface toresemble a first brick pattern; thermoforming the second panel to formthe second three-dimensional front surface and the second rear surfacecomprises forming the second three-dimensional front surface to resemblea second brick pattern; thermoforming the third panel to form the thirdthree-dimensional front surface and the third rear surface comprisesforming the third three-dimensional front surface to resemble a thirdbrick pattern; and thermoforming the fourth panel to form the fourththree-dimensional front surface and the fourth rear surface comprisesforming the fourth three-dimensional front surface to resemble a fourthbrick pattern.
 56. The method of claim 53, wherein forming the firstpanel sub-assembly by facing the first rear surface of the first paneltowards the second rear surface of the second panel comprises: couplingthe first panel and the second panel to a first frame.
 57. The method ofclaim 56, wherein forming the second panel sub-assembly by facing thethird rear surface of the third panel towards the fourth rear surface ofthe fourth panel comprises: coupling the third panel and the fourthpanel to a second frame.
 58. A method of manufacturing a double-sidedwall assembly, comprising: thermoforming a first panel to form a firstthree-dimensional front surface and a first rear surface; thermoforminga second panel to form a second three-dimensional front surface and asecond rear surface; forming a first panel sub-assembly by coupling thefirst panel to the second panel such that first rear surface faces thesecond rear surface; thermoforming a third panel to form a thirdthree-dimensional front surface and a third rear surface; thermoforminga fourth panel to form a fourth three-dimensional front surface and afourth rear surface; forming a second panel sub-assembly by coupling thethird panel to the fourth panel such that third rear surface faces thefourth rear surface; and coupling the first panel sub-assembly to thesecond panel sub-assembly in a side-by side arrangement.
 59. The methodof claim 58, wherein coupling the first panel sub-assembly to the secondpanel sub-assembly in the side-by side arrangement comprises: couplingthe first panel sub-assembly and the second panel sub-assembly to apost.
 60. The method of claim 58, wherein: thermoforming the first panelto form the first three-dimensional front surface and the first rearsurface comprises forming the first three-dimensional front surface toresemble a first brick pattern; thermoforming the second panel to formthe second three-dimensional front surface and the second rear surfacecomprises forming the second three-dimensional front surface to resemblea second brick pattern; thermoforming the third panel to form the thirdthree-dimensional front surface and the third rear surface comprisesforming the third three-dimensional front surface to resemble a thirdbrick pattern; and thermoforming the fourth panel to form the fourththree-dimensional front surface and the fourth rear surface comprisesforming the fourth three-dimensional front surface to resemble a fourthbrick pattern.
 61. The method of claim 58, wherein forming the firstpanel sub-assembly by facing the first rear surface of the first paneltowards the second rear surface of the second panel comprises: couplingthe first panel and the second panel to a first frame.
 62. The method ofclaim 61, wherein forming the second panel sub-assembly by facing thethird rear surface of the third panel towards the fourth rear surface ofthe fourth panel comprises: coupling the third panel and the fourthpanel to a second frame.
 63. A method of manufacturing a double-sidedwall assembly, comprising: providing a first panel sub-assembly having afirst pair of panels coupled in a back-to-back arrangement; forming eachfront surface of the first pair of panels with a first three-dimensionalbrick pattern; providing a second panel sub-assembly having a secondpair of panels coupled in a back-to-back arrangement; forming each frontsurface of the second pair of panels with a second three-dimensionalbrick pattern; coupling the first panel sub-assembly to the second panelsub-assembly in a side-by-side arrangement.
 64. The method of claim 63,wherein coupling the first panel sub-assembly to the second panelsub-assembly in a side-by-side arrangement comprises: coupling the firstpanel sub-assembly and the second panel sub-assembly to a post.
 65. Themethod of claim 63, wherein providing the first panel sub-assemblyhaving the first pair of panels coupled in the back-to-back arrangementcomprises: coupling the first pair of panels to a first frame.
 66. Themethod of claim 65, wherein providing the second panel sub-assemblyhaving the second pair of panels coupled in the back-to-back arrangementcomprises: coupling the second pair of panels to a second frame.